Volvo XC90
Turbocharged five-cylinder with 2.5 litres and 154 kW, manufactured in Skövde, Sweden. Mitsubishi turbocharger with intercooling for strong mid-range torque. Chain drive; popular as a harmonious all-round engine without extreme peaks.
Adequate for the family SUV
In the XC90 the T5 is somewhat muted. Adequate for relaxed touring, no sporting statement.
Engine Weaknesses 4
Replacement interval 160,000 km or 10 years. Timing belt drives water pump. An old pump failing after a belt change can instantly destroy the new belt.
Symptoms: No warning signal. Missed service causes engine damage without warning.
Plastic PCV system hoses become brittle and crack, separator clogs with sludge. Crankcase vacuum draws oil past camshaft and crankshaft seals.
Symptoms: Whistling noise from under bonnet, oil spots on underbody at rear of engine, rising oil consumption, smoke from engine bay.
The turbocharger oil drain line seals with O-rings that stretch at higher mileage. Oil loss at the turbo housing and increased oil consumption follow.
Symptoms: Blue smoke after coasting, oil accumulation under the vehicle near the turbo, oil consumption 0.5–1 L per 1,000 km.
Valve cover gasket and spark plug tube seals become porous with age. Oil runs into spark plug wells and causes misfires.
Symptoms: Misfires (cylinders 1–5), rough engine running, oily spark plugs, P030x fault codes.
Vehicle Weaknesses 7
The Aisin Warner AW55-50/51SN gearbox in the XC90 I is regarded as its biggest weakness: from 100,000 km it shifts harshly and with unusually long gear-change intervals. Valve body faults often require a complete transmission overhaul.
The Haldex all-wheel drive system on early XC90 models (pre-2007) shows wear at the coupling and differential. If the damage is not corrected, the entire drivetrain can fail.
The optional air suspension compressor on the XC90 I overheats or freezes in sub-zero temperatures. Moisture in the compressor and pipes freezes at around -5°C and blows the fuse. Repair at the dealer around €1,600.
On the XC90 I, tie rod ends (especially outer), ball joints and control arms at the front axle wear out. This leads to wheel misalignment and heavy one-sided tyre wear. Replace early to avoid consequential damage.
The front subframe behind the radiator is known for corrosion, especially on vehicles from road-salt regions. Visible rust on the subframe requires treatment and sealing (€600+).
The nav and audio system of the XC90 I fails due to cold solder joints in the RTI control unit — a known Volvo issue of this era. Replacement units cost over €700; professional re-soldering is cheaper.
Rear control arm bushings deteriorate after approximately 150,000 km. Knocking over bumps and unstable handling are the result. Replacement costs €500–900.
Reports & Tests
957 owner complaints filed with NHTSA (2002–2014). Most reported: Electrical (276), Powertrain (275), Engine (85).